Internal and external donor compounds for olefin polymerization catalysts ii

ABSTRACT

The present invention relates to catalyst systems containing solid catalyst components comprising titanium, magnesium, halogen and an internal electron donor compound having at least one ether group and at least one ketone group; organoaluminum compounds and alkyl benzoate derivatives as external electron donors. The present invention also relates to methods of making the catalyst systems, and methods of polymerizing or copolymerizing alpha-olefins using the catalyst systems.

TECHNICAL FIELD

The present invention relates to olefin polymerization catalyst systems. In particular, the present invention relates to catalyst systems comprising a solid catalyst component containing titanium, magnesium, halogen and an internal electron donor compound having at least one ether group and at least one ketone group; an organoaluminum compound; and an alkyl benzoate derivative as an external electron donor compound. The present invention further relates to methods of making the catalyst systems and methods of polymerizing or copolymerizing alpha-olefins using the catalyst systems.

BACKGROUND

Polyolefins are a class of polymers derived from simple olefins. Known methods of making polyolefins involve the use of Ziegler-Natty polymerization catalysts. These catalysts polymerize vinyl monomers using a transition metal halide to provide a polymer with an isotactic stereochemical configuration.

Basically two types of Ziegler-Natta catalyst systems are used in the normal processes for the polymerization or copolymerization of olefins. The first one, in its broadest definition, comprises TiCl₃ based catalysts components, obtained for example by reduction of TiCl₄ with Al-alkyls, used in combination with Al-compounds such as diethylaluminum chloride (DEAC). Despite the modest properties of the polymers in terms of isotacticity the catalysts are characterized by a very low activity which causes the presence of large amounts of catalytic residues in the polymers.

The second type of catalyst system comprises a solid catalyst component, constituted by a magnesium dihalide on which are supported a titanium compound and an internal electron donor compound. In order to maintain the high selectivity for an isotactic polymer product, a variety of internal electron donor compounds must be added during the catalyst synthesis. Conventionally, when a higher crystallinity of the polymer is required, also an external donor compound is added during the polymerization reaction. Both the internal and external electron donor compounds become indispensible compositions of catalyst components.

During the past 30 years, numerous supported Ziegler-Natta catalysts have been developed which afford a much higher activity in olefin polymerization reactions and much higher contents of crystalline isotactic fractions in the polymers they produce. With the development of internal and external electron donor compounds, polyolefin catalyst system is continuously renovated.

SUMMARY

The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Rather, the sole purpose of this summary is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented hereafter.

The present invention provides olefin polymerization catalyst systems containing solid catalyst components, methods of making the catalyst systems, and methods of polymerizing and copolymerizing olefins involving the use of the catalyst systems. The solid catalyst components comprise titanium, magnesium, halogen, and an internal electron donor compound containing at least one ether group and at least one ketone group. The catalyst systems can contain a solid catalyst component, an organoaluminum compound, and an alkyl benzoate derivative as an external electron donor compound. The solid catalyst component can be made by contacting a magnesium compound and a titanium compound with an internal electron donor compound containing at least one ether group and at least one ketone group. The methods of polymerizing or copolymerzing olefins involve contacting olefins with catalyst systems containing a solid catalyst component, an organoaluminum compound, and an alkyl benzoate derivative.

To the accomplishment of the foregoing and related ends, the invention involves the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects and implementations of invention. These are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

BRIEF SUMMARY OF THE DRAWINGS

FIG. 1 is a high level schematic diagram of an olefin polymerization system in accordance with one aspect of the present invention.

FIG. 2 is a schematic diagram of an olefin polymerization reactor in accordance with one aspect of the present invention.

FIG. 3 is a high level schematic diagram of a system for making impact copolymer in accordance with one aspect of the present invention.

DETAILED DESCRIPTION

The present invention relates to solid catalyst components containing titanium, magnesium, halogen and a compound containing at least one ether group and at least one ketone group in olefinic polymerization; olefin polymerization catalyst systems containing the solid catalyst components, organoaluminums, and alkyl benzoate derivatives; methods of making the solid catalyst components and the catalyst systems; and methods of polymerizing and copolymerizing olefins using the catalyst systems.

An aspect of the invention is a solid catalyst component containing titanium, magnesium, halogen and an internal electron donor compound. The internal electron donor compound contains at least one ether group and at least one ketone group. In particular, the solid catalyst component comprises a titanium compound having at least one titanium-halogen bond and an internal electron donor compound containing at least one ether group and at least one ketone group supported on a magnesium halide crystal lattice. The titanium compound is TiCl₄ or TiCl₃. In one embodiment, the magnesium halide crystal lattice is a magnesium dichloride crystal lattice, which is widely known from the patent literature as a support for Ziegler-Natta catalysts.

Use of the internal electron donor compound containing at least one ether group and at least one ketone group contributes to improved performance characteristics of resultant catalysts, such as high/improved catalyst activity, high/improved hydrogen response, and the ability to produce polyolefins with desired/controllable crystallinity measured by xylene soluble values, desired/controllable molecular weight measured by melt flow indexes, and the like.

The solid catalyst component of the present invention is a highly active catalyst component containing a reaction product of a titanium compound, a magnesium compound, and an internal electron donor compound containing at least one ether group and at least one ketone group. The titanium compounds used in the preparation of the solid catalyst component include, for example, a tetravalent titanium compound represented by chemical formula (I):

Ti(OR)_(g)X_(4-g)  (I)

wherein R represents a hydrocarbon group, preferably an alkyl group having 1 to about 20 carbon atoms, X represents a halogen atom, and 0≦g≦4. Specific examples of the titanium compound include, but are not limited to titanium tetrahalides such as TiCl₄, TiBr₄ and TiI₄; alkoxytitanium trihalides such as Ti(OCH₃)Cl₃, Ti(OC₂H₅)Cl₃, Ti(O-n-C₄H₉)Cl₃, Ti(OC₂H₅)Br₃ and Ti(O-i-C₄H₉)Br₃; dialkoxytitanium dihalides such as Ti(OCH₃)₂Cl₂, Ti(OC₂H₅)₂Cl₂, Ti(O-n-C₄H₉)₂Cl₂ and Ti(OC₂H₅)₂Br₂; trialkoxytitanium monohalides such as Ti(OCH₃)₃Cl, Ti(OC₂H₅)₃Cl, Ti(O-n-C₄H₉)₃Cl and Ti(OC₂H₅)₃Br; and tetraalkoxytitaniums such as Ti(OCH₃)₄, Ti(OC₂H₅)₄ and Ti(O-n-C₄H₉)₄. Among these, the halogen containing titanium compounds, especially titanium tetrahalides, are preferred in some instances. These titanium compounds may be used individually or in solutions of hydrocarbon compounds or halogenated hydrocarbons.

The magnesium compounds used in the preparation of the solid catalyst component include, for example, a magnesium compound having no reducibility. In one embodiment, the magnesium compound having no reducibility is a halogen containing magnesium compound. Specific examples of the magnesium compounds having no reducibility include, but are not limited to magnesium halides such as magnesium chloride, magnesium bromide, magnesium iodide and magnesium fluoride; alkoxy magnesium halides such as methoxy magnesium chloride, ethoxy magnesium chloride, isopropoxy magnesium chloride, butoxy magnesium chloride and octoxy magnesium chloride; aryloxy magnesium halides such as phenoxy magnesium chloride and methylphenoxy magnesium chloride; alkoxy magnesiums such as ethoxy magnesium, isopropoxy magnesium, butoxy magnesium, n-octoxy magnesium and 2-ethylhexoxy magnesium; aryloxy magnesiums such as phenoxy magnesium and dimethylphenoxy magnesium; and carboxylic acid salts of magnesium such as magnesium laurate and magnesium stearate. These magnesium compounds may be in the liquid or solid states.

In one aspect, halogen containing magnesium compounds, such as magnesium chloride, alkoxy magnesium chlorides and aryloxy magnesium chlorides, are employed

When preparing the solid catalyst component, an internal electron donor can be used/added. The solid catalyst component can be made by contacting a magnesium compound and a titanium compound with an internal electron donor. In one embodiment, the solid catalyst component is made by contacting a magnesium compound and a titanium compound in the presence of an internal electron donor. In another embodiment, the solid catalyst component is made by forming a magnesium based catalyst support optionally with the titanium compound and optionally with the internal electron donor, and contacting the magnesium based catalyst support with the titanium compound and the internal electron donor.

The internal electron donor contains at least one ether group and at least one ketone group. That is, the internal electron donor compound contains in its structure at least one ether group and at least one ketone group.

Examples of internal electron donors containing at least one ether group and at least one ketone group include compounds of the following chemical formula (II):

wherein R¹, R², R³, and R⁴ are identical or different, and each represents a substituted or unsubstituted hydrocarbon group. In one embodiment, the substituted or unsubstituted hydrocarbon group includes from 1 to about 30 carbon atoms. In another embodiment, R¹, R², R³, and R⁴ are identical or different, and each represents a linear or branched alkyl group containing from 1 to about 18 carbon atoms, a cycloaliphatic group containing from about 3 to about 18 carbon atoms, an aryl group containing from about 6 to about 18 carbon atoms, an alkylaryl group containing from about 7 to about 18 carbon atoms, or an arylalkyl group containing from about 7 to about 18 carbon atoms. In yet another embodiment, R¹, C¹ and R² are a part of a substituted or unsubstituted cyclic or polycyclic structure containing from about 5 to about 20 carbon atoms. In still yet another embodiment, the cyclic or polycyclic structure has one or more substitutes selected from the group consisting of a linear or branched alkyl group containing from 1 to about 18 carbon atoms, a cycloaliphatic group containing from about 3 to about 18 carbon atoms, an aryl group containing from about 6 to about 18 carbon atoms, an alkylaryl group containing from about 7 to about 18 carbon atoms, and an arylalkyl group containing from about 7 to about 18 carbon atoms.

Specific examples of internal electron donors containing at least one ether group and at least one ketone group include 9-(alkylcarbonyl)-9′-alkoxymethylfluorene such as 9-(methylcarbonyl)-9′-methoxymethylfluorene, 9-(methylcarbonyl)-9′-ethoxymethylfluorene, 9-(methylcarbonyl)-9′-propoxymethylfluorene, 9-(methylcarbonyl)-9′-butoxymethylfluorene, 9-(methylcarbonyl)-9′-pentoxymethylfluorene, 9-(ethylcarbonyl)-9′-methoxymethylfluorene, 9-(ethylcarbonyl)-9′-ethoxymethylfluorene, 9-(ethylcarbonyl)-9′-propoxymethylfluorene, 9-(ethylcarbonyl)-9′-butoxymethylfluorene, 9-(ethylcarbonyl)-9′-pentoxymethylfluorene, 9-(propylcarbonyl)-9′-methoxymethylfluorene, 9-(propylcarbonyl)-9′-ethoxymethylfluorene, 9-(propylcarbonyl)-9′-propoxymethylfluorene, 9-(propylcarbonyl)-9′-butoxymethylfluorene, 9-(propylcarbonyl)-9′-pentoxymethylfluorene, 9-(butylcarbonyl)-9′-methoxymethylfluorene, 9-(butylcarbonyl)-9′-ethoxymethylfluorene, 9-(butylcarbonyl)-9′-propoxymethylfluorene, 9-(butylcarbonyl)-9′-butoxymethylfluorene, 9-(butylcarbonyl)-9′-pentoxymethylfluorene, 9-(isobutylcarbonyl)-9′-methoxymethylfluorene, 9-(isobutylcarbonyl)-9′ethoxymethylfluorene, 9-(isobutylcarbonyl)-9′-propoxymethylfluorene, 9-(isobutylcarbonyl)-9′-butoxymethylfluorene, 9-(isobutylcarbonyl)-9′-pentoxymethylfluorene, 9-(pentylcarbonyl)-9′-methoxymethylfluorene, 9-(pentylcarbonyl)-9′-ethoxymethylfluorene, 9-(pentylcarbonyl)-9′-propoxymethylfluorene, 9-(pentylcarbonyl)-9′-butoxymethylfluorene, 9-(pentylcarbonyl)-9′-pentoxymethylfluorene, 9-(hexylcarbonyl)-9′-methoxymethylfluorene, 9-(hexylcarbonyl)-9′-ethoxymethylfluorene, 9-(hexylcarbonyl)-9′-propoxymethylfluorene, 9-(hexylcarbonyl)-9′-butoxymethylfluorene, 9-(hexylcarbonyl)-9′-pentoxymethylfluorene, 9-(octylcarbonyl)-9′-methoxymethyl fluorene, 9-(octylcarbonyl)-9′-ethoxymethylfluorene, 9-(octylcarbonyl)-9′-propoxymethylfluorene, 9-(octylcarbonyl)-9′-butoxymethylfluorene, 9-(octylcarbonyl)-9′-pentoxymethylfluorene; 9-(i-octylcarbonyl)-9′-methoxymethylfluorene, 9-(i-octylcarbonyl)-9′-ethoxymethylfluorene, 9-(i-octylcarbonyl)-9′-propoxymethylfluorene, 9-(i-octylcarbonyl)-9′-butoxymethylfluorene, 9-(i-octylcarbonyl)-9′-pentoxymethylfluorene; 9-(nonylcarbonyl)-9′-methoxymethylfluorene, 9-(nonylcarbonyl)-9′-ethoxymethylfluorene, 9-(nonylcarbonyl)-9′-propoxymethylfluorene, 9-(nonylcarbonyl)-9′-butoxymethylfluorene, 9-(nonylcarbonyl)-9′-pentoxymethylfluorene; 9-(i-nonylcarbonyl)-9′-methoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-ethoxymethylfluorene, 9-(i-nonylcaxbortyl)-9′-propoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-butoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-pentoxymethylfluorene; 9-(2-ethyl-hexylcarbonyl)-9′-methoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-ethoxymethylfluorene, 9-(2-ethyl-hex ylcarbonyl)-9′-propoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-butoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-pentoxymethylfluorene, 9-(phenylketone)-9′-methoxymethylfluorene, 9-(phenylketone)-9′-ethoxymethylfluorene, 9-(phenylketone)-9′-propoxymethylfluorene, 9-(phenylketone)-9′-butoxymethylfluorene, 9-(phenylketone)-9′-pentoxymethylfluorene, 9-(4-methylphenylketone)-9′-methoxymethylfluorene, 9-(3-methylphenylketone)-9′-methoxymethylfluorene, 9-(2-methylphenylketone)-9′-methoxymethylfluorene.

Additional examples include: 1-(ethylcarbonyl)-1′-rnethoxymethylcyclopentane, 1-(propylcarbonyl)-1′-methoxymethylcyclopentane, 1-(i-propylcarbonyl)-1′-methoxymethylcyclopentane, 1-(butylcarbonyl)-1′-methoxymethylcyclopentane, 1-(1-butylcarbonyl)-1′-methoxymethylcyclopentane, 1-(pentylcarbonyl)-1′-methoxymethylcyclopentane, 1-(i-pentylcarbonyl)-1′-rnethoxymethylcyclopentane, 1-(neopentylcarbonyl)-1′-methoxymethylcyclopentane, 1-(hexylcarbonyl)-1′-rnethoxymethylcyclopentane, 1-(2-ethylhexylcarbonyl)-1′-methoxymethylcyclopentane, 1-(octylcarbonyl)-1′-methoxymethylcyclopentane, 1-(i-octylcarbonyl)-1′-methoxymethylcyclopentane, 1-(nonylcarbonyl)-1′-methoxymethylcyclopentane, 1-(i-nonylcarbonyl)-1′-methoxymethylcyclopentane, 1-(ethylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(propylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(i-propylcarbonyl)-1′-methoxymethyl-2-methyl-cyclopentane, 1-(butylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(i-butylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane. 1-(pentylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(neopentylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(hexylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(2-ethylhexylcarbonyl)-1-methoxymethyl-2-methyl cyclopentane, 1-(octylcarbonyl)-1′-methoxymethyl-2-methyl cyclopentane, 1-(i-octylcarbonyl)-1′-methoxymethyl-2-methyl cyclopentane, 1-(nonylcarbonyl)-1′-methoxymethyl-2-methyl cyclopentane, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2-methylcyclopentane, 1-(ethylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(propylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-cyclopentane, 1-(butylcarbonyl)-1′-methoxymethyl-2,5-di-cyclopentane, 1-(i-butylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(pentylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(hexylcarbonyl)-1′-methoxymethyl-2,5-dimethylcyclopentane, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,5-dimethyl cyclopentane, 1-(octylcarbonyl)-1′-methoxymethyl-2,5-dimethyl cyclopentane, 1-(i-octyl carbonyl)-1′-methoxymethyl-2,5-dimethyl cyclopentane, 1-(nonylcarbonyl)-1′-methoxymethyl-2,5-dimethyl cyclopentane, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,5-dimethyl cyclopentane, 1-(ethyl carbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(propyl carbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(butylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(1-butylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(pentylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(octylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(i-octylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(nonylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,4-cyclopentadiene, 1-(ethylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(propylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(i-propylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(butylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(i-butyl carbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(pentylcarbonyl)-1-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(octylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(i-octylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(nonylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2-methyl-2,4-cyclopentadiene, 1-(ethylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(propylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(butylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(i-butylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(pentylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(1-pentylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(octylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(i-octylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(nonylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,5-dimethyl-2,4-cyclopentadiene, 1-(ethylcarbonyl)-1′-methoxymethylcyclohexane, 1-(propylcarbonyl)-1′-methoxymethylcyclohexane, 1-(i-propylcarbonyl)-1′-methoxymethylcyclohexane, 1-(butylcarbonyl)-1′-methoxymethylcyclohexyl 1-(i-butylcarbonyl)-1′-methoxymethylcyclohexane, 1-(pentylcarbonyl)-1′-methoxymethylcyclohexane, 1-(i-pentylcarbonyl)-1′-methoxymethylcyclohexane, 1-(neopentylcarbonyl)-1′-methoxymethylcyclohexane, 1-(hexylcarbonyl)-1′-methoxymethylcyclohexane, 1-(2-ethylhexylcarbonyl)-1′-methoxymethylcyclohexane, 1-(octylcarbonyl)-1′-methoxymethylcyclohexane, 1-(i-octylcarbonyl)-1′-methoxymethylcyclohexane, 1-(i-nonylcarbonyl)-1′-methoxymethylcyclohexane, 1-(ethylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(propylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(i-propyl carbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(butylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(i-butylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(pentylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(neopentylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(hexylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(octylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(i-octylcarbonyl)-1′-methoxymethyl-2-methylcyclohexane, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2-methyl cyclohexane, 1-(ethylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(propylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-cyclohexane, 1-(butylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-cyclohexane, 1-(i-butylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(pentylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(hexylcarbonyl)-1′-methoxymethyl-2,6-dimethylcyclohexane, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,6-dimethyl cyclohexane, 1-(oetylcarbonyl)-1′-methoxymethyl-2,6-dimethyl cyclohexane, 1-(i-oetylcarbonyl)-1′-methoxymethyl-2,6-dimethyl cyclohexane, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,6-dimethyl cyclohexane, 2,5-dimethyl-3-ethylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-propylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-propylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-butylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-i-butylcarbonyl-1′-methoxymethylcyclohexyl, 1-(ethylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(propylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(butylcarbonyl)-1′-methoxymethylcyclohexyl, 1-(1-butyl carbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(pentylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(1-pentylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(oetylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(i-oetylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,5-cyclohexadiene, 1-(ethylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(propylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(i-propanecarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(butylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(i-butylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(pentylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(1-pentylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(octylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(1-octylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2-methyl-2,5-cyclohexadiene, 1-(ethylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(propylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(i-propylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(butylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(i-butylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(pentylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(i-pentylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(neopentylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(hexylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(2-ethylhexylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(octylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(i-octylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 1-(i-nonylcarbonyl)-1′-methoxymethyl-2,6-dimethyl-2,5-cyclohexadiene, 2,5-dimethyl-3-ethylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-propylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-i-propylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-butylcarbonyl-3′-methoxymethylpentane, 2,5-dimethyl-3-i-butylcarbonyl-1′-methoxymethylcyclohexyl, 4-isopropyl-4-(methoxymethyl)-7-methyloctan-3-one, 5-isopropyl-5-(methoxymethyl)-2,8-dimethylnonan-4-one, 5-isopropyl-5-(methoxymethyl)-8-methylnonan-4-one, 6-isopropyl-6-(methoxymethyl)-9-methyldecan-5-one, 5-isopropyl-5-(methoxymethyl)-2-methylundecan-6-one, 5-isopropyl-5-(methoxymethyl)-2-methyldodecan-6-one, 5-isopropyl-5-(methoxymethyl)-2-methyltridecan-6-one, 4-isopentyl-4-(methoxymethyl)-7-methyloctan-3-one, 5-isopentyl-5-(methoxymethyl)-8-methylnonan-4-one, 6-isopentyl-6-(methoxymethyl)-9-methyldecan-5-one, 5-isopentyl-5-(methoxymethyl)-2-methylundecan-6-one, 5-isopentyl-5-(methoxymethyl)-2-methyldodecan-6-one, 5-isopentyl-5-(methoxymethyl)-2-methyltridecan-6-one, 4-isobutyl-4-(methoxymethyl)-6-methylheptan-3-one, 5-isobutyl-5-(methoxymethyl)-7-methyloctan-4-one, 4-isobutyl-4-(methoxymethyl)-2-methylnonan-5-one, 4-isobutyl-4-(methoxymethyl)-2-methyldecan-5-one, and 4-isobutyl-4-(methoxymethyl)-2-methylundecan-5-one.

The internal electron donor compounds may be used individually or in combination. In employing the internal electron donor compounds, they do not have to be used directly as starting materials, but compounds convertible to the electron donors in the course of preparing the solid catalyst components may also be used as the starting materials.

The solid catalyst component can be made by contacting a magnesium compound and a titanium compound with an internal electron donor compound containing at least one ether group and at least one ketone group. In one embodiment, the solid catalyst component is made by contacting a magnesium compound and a titanium compound in the presence of an internal electron donor compound containing at least one ether group and at least one ketone group. In another embodiment, the solid catalyst component is made by forming a magnesium based catalyst support/catalyst crystal lattice optionally with a titanium compound and optionally with an internal electron donor compound containing at least one ether group and at least one ketone group, and contacting the magnesium based catalyst support/catalyst crystal lattice with the titanium compound and the internal electron donor compound containing at least one ether group and at least one ketone group. In yet another embodiment, the solid catalyst component is made by contacting a magnesium based catalyst support/catalyst crystal lattice with a titanium compound to form a mixture, then contacting the mixture with an internal electron donor compound containing at least one ether group and at least one ketone group. In still yet another embodiment, the solid catalyst component is made by contacting a magnesium based catalyst support catalyst crystal lattice with a titanium compound to form a mixture, then contacting the mixture with an internal electron compound containing at least one ether group and at least one ketone group, then contacting the mixture again with the internal electron donor compound containing at least one ether group and at least one ketone group. Such repeated contact with the internal electron donor compound containing at least one ether group and at least one ketone group can occur once, twice, three times, four times or more, successively or with other acts performed between contacts with additional doses of the internal electron donor compounds containing at least one ether group and at least one ketone group.

Generally speaking, the magnesium based catalyst support/catalyst crystal lattice is made by dissolving a magnesium compound in a solvent mixture comprising an organic epoxy compound, an organic phosphorus compound and an optional inert diluent to form a homogenous solution.

The organic epoxy compounds used in the present invention include compounds having at least one epoxy group in the forms of monomers, dimmers, oligomers and polymers. Examples of epoxy compounds include, but are not limited to aliphatic epoxy compounds, alicyclic epoxy compounds, aromatic epoxy compounds, or the like. Examples of aliphatic epoxy compounds include, but are not limited to halogenated aliphatic epoxy compounds, aliphatic epoxy compounds having a keto group, aliphatic epoxy compounds having an ether bond, aliphatic epoxy compounds having an ester bond, aliphatic epoxy compounds having a tertiary amino group, aliphatic epoxy compounds having a cyano group, or the like. Examples of alicyclic epoxy compounds include, but are not limited to halogenated alicyclic epoxy compounds, alicyclic epoxy compounds having a keto group, alicyclic epoxy compounds having an ether bond, alicyclic epoxy compounds having an ester bond, alicyclic epoxy compounds having a tertiary amino group, alicyclic epoxy compounds having a cyano group, or the like. Examples of aromatic epoxy compounds include, but are not limited to halogenated aromatic epoxy compounds, aromatic epoxy compounds having a keto group, aromatic epoxy compounds having an ether bond, aromatic epoxy compounds having an ester bond, aromatic epoxy compounds having a tertiary amino group, aromatic epoxy compounds having a cyano group, or the like.

Specific examples of epoxy compounds include, but are not limited to epifluorohydrin, epichlorohydrin, epibromohydrin, hexafluoropropylene oxide, 1,2-epoxy-4-fluorobutane, 1-(2,3-epoxypropyl)-4-fluorobenzene, 1-(3,4-epoxybutyl)-2-fluorobenzene, 1-(2,3-epoxypropyl)-4-chlorobenzene, 1-(3,4-epoxybutyl)-3-chlorobenzene, or the like. Specific examples of halogenated alicyclic epoxy compounds include 4-fluoro-1,2-cyclohexene oxide, 6-chloro-2,3 epoxybicyclo[2,2,1]heptane, or the like. Specific examples of halogenated aromatic epoxy compounds include 4-fluorostyrene oxide, 1-(1,2-epoxypropyl)-3-trifluorobenzene, or the like.

The organic phosphorus compounds used in the present invention include, but are not limited to hydrocarbyl esters and halohydrocarbyl esters of ortho-phosphoric acid and phosphorous acid. Specific examples include, but are not limited to trimethyl phosphate, triethyl phosphate, tributyl phosphate, triphenyl phosphate, trimethyl phosphite, triethyl phosphite, tributyl phosphite and triphenyl phosphite.

For more sufficiently dissolving a magnesium compound, an inert diluent is optionally added in the solvent mixture. The inert diluent can typically be aromatic hydrocarbons or alkanes, as long as it can facilitate the dissolution of the magnesium compound. Examples of aromatic hydrocarbons include, but are not limited to benzene, toluene, xylene, chlorobenzene, dichlorobenzene, trichlorobenzene, chlorotoluene, and derivatives thereof. Examples of alkanes include linear, branched, or cyclic alkanes having about 3 to about 30 carbons, such as butane, pentane, hexane, cyclohexane, heptanes, and the like. These inert diluents may be used alone or in combination.

In embodiments of making the solid catalyst component according to the Examples, the magnesium based catalyst support/catalyst crystal lattice is mixed with a titanium compound such as liquid titanium tetrahalide to form a solid precipitate in the optional presence of an auxiliary precipitant. The auxiliary precipitant may be added before, during or after the precipitation of the solids and loaded on the solids.

The auxiliary precipitants used in the present invention include carboxylic acids, carboxylic acid anhydrides, ethers, ketones, or mixture thereof. Specific examples include, but are not limited to acetic anhydride, phthalic anhydride, succinic anhydride, maleic anhydride, 1,2,4,5-benzene tetracarboxylic dianhydride, acetic acid, propionic acid, butyric acid, acrylic acid, methacrylic acid, acetone, methyl ethyl ketone, benzophenone, dimethyl ether, diethyl ether, dipropyl ether, dibutyl ether, and dipentyl ether.

The process of solids precipitation can be carried out by at least one of three methods. One method involves mixing a titanium compound such as liquid titanium tetrahalide with a magnesium based catalyst support/catalyst crystal lattice at a temperature in the range of about −40 degree Celsius to about 0 degree Celsius, and precipitating the solids while the temperature is raised slowly to a range from about 30 degrees Celsius to about 120 degrees Celsius, such as from about 60 degrees Celsius to about 100 degrees Celsius. The second method involves adding a titanium compound dropwise into a magnesium based catalyst support/catalyst crystal lattice at low or room temperature to precipitate out solids immediately. The third method involves adding a first titanium compound dropwise into a magnesium based catalyst support/catalyst crystal lattice and mixing a second titanium compound with the magnesium catalyst support/catalyst crystal lattice. In these methods, an internal electron donor compound containing at least one ether group and at least one ketone group can be desirably present in the reaction system. The internal electron donor compound containing at least one ether group and at least one ketone group can be added either after the magnesium based catalyst support (catalyst crystal lattice is obtained or after the solid precipitate is formed.

In one embodiment, when the solid catalyst component is formed, a surfactant can be used. The surfactant can contribute to many of the beneficial properties of the solid catalyst component and the catalyst system. General examples of surfactants include polymer surfactants, such as polyacrylates, polymethacrylates, polyalkyl methacrylates, and the like. A polyalkyl methacrylate is a polymer that may contain one or more methacrylate monomers, such as at least two different methacrylate monomers, at least three different methacrylate monomers, etc. Moreover, the acrylate and methacrylate polymers may contain monomers other than acrylate and methacrylate monomers, so long as the polymer surfactant contains at least about 40% by weight of acrylate and methacrylate monomers.

In one embodiment, non-ionic surfactants and/or anionic surfactants can be used. Examples of non-ionic surfactants and/or anionic surfactants include, but are not limited to phosphate esters, alkyl sulfonates, aryl sulfonates, alkylaryl sulfonates, linear alkyl benzene sulfonates, alkylphenols, ethoxylated alcohols, carboxylic esters, fatty alcohols, fatty esters, fatty aldehydes, fatty ketones, fatty acid nitriles, benzene, naphthalene, anthracene, succinic anhydride, phthalic anhydrides, rosin, terpene, phenol, or the like. In fact, a number of anhydride surfactants are effective. In some instances, the absence of an anhydride surfactant causes the formation of very small catalyst support particles while the over-use creates straw shaped material sometimes referred to as needles.

The solid catalyst precursor can be formed in the following way. In a solvent such as toluene, a magnesium and titanium containing solution is seen following the addition of a halogenating agent such as TiCl₄ into a magnesium based solution at relatively cooler temperatures, such as −25 degrees Celsius until about 0 degrees Celsius. An oil phase is then formed, which can be dispersed into the hydrocarbon phase that is stable until about 40 degrees Celsius. The resultant magnesium material becomes a semi-solid at this point and the particle morphology is now determined. The semi-solid converts to a solid between about 40 degrees Celsius and about 80 degrees Celsius.

To facilitate obtaining uniform solid particles, the process of precipitation can be carried out slowly. When the second method of adding titanium halide dropwise at low or room temperature is applied, the process may take place over a period from about 1 hour to about 6 hours. When the first method of raising the temperature in a slow manner is applied, the rate of temperature increase can range from about 4 degrees Celsius to about 125 degrees Celsius per hour.

The solid precipitate is first separated from the mixture. In the solid precipitate thus obtained may be entrained a variety of complexes and byproducts, so that further treatment may in some instances be necessary. In one embodiment, the solid precipitate is treated with a titanium compound to substantially remove the byproducts from the solid precipitate.

The solid precipitate can be washed with an inert diluent and then treated with a titanium compound or a mixture of a titanium compound and an inert diluent. The titanium compound used in this treatment can be identical to or different from the titanium compound used for forming the solid precipitate. The amount of titanium compound used is from about 1 to about 20 moles, such as from about 2 to about 15 moles, per mole of magnesium compound in the support. The treatment temperature ranges from about 50 degrees Celsius to about 150 degrees Celsius, such as from about 60 degrees Celsius to about 100 degrees Celsius. If a mixture of titanium tetrahalide and an inert diluent is used to treat the solid precipitate, the volume % of titanium tetrahalide in the treating solution is from about 10% to about 100%, the rest being the inert diluent.

The treated solids can be further washed with an inert diluent to remove ineffective titanium compounds and other byproducts. The inert diluent herein used can be hexane, heptanes, octane, 1,2-dichloroethane, benzene, toluene, ethylbenzene, xylene, and other hydrocarbons.

By treating the solid precipitate with the titanium compound and optionally an inert diluent, the byproducts in the solid precipitate can be removed from the solid precipitate. In one embodiment, the solid precipitate is treated with the titanium compound and optionally an inert diluent about two times or more and five times or less.

By treating the solid precipitate with an inert diluent, a free titanium compound in the solid precipitate can be removed from the solid precipitate. As a result, the resultant solid precipitate does not substantially contain a free titanium compound. In one embodiment, the solid precipitate is treated repeatedly with an inert diluent until the filtrate contains about 100 ppm or less of titanium. In another embodiment, the solid precipitate is treated repeatedly with an inert diluent until the filtrate contains about 50 ppm or less of titanium. In yet another embodiment, the solid precipitate is treated with an inert diluent until the filtrate contains about 10 ppm or less of titanium. In one embodiment, the solid precipitate is treated with an inert diluent about three times or more and seven times or less.

In one embodiment, the solid catalyst component contains from about 0.5 to about 6.0 wt % titanium; from about 10 to about 25 wt % magnesium; from about 40 to about 70 wt % halogen; from about 1 to about 50 wt % the internal electron donor; and optionally inert diluent from about 0 to about 15 wt %. In another embodiment, the solid catalyst component contains from about 2 to about 25 wt % of one or more of the internal electron donors. In yet another embodiment, the solid catalyst component contains from about 5 to about 20 wt % of one or more of the internal electron donors.

The amounts of the ingredients used in preparing the solid catalyst component may vary depending upon the method of preparation. In one embodiment, from about 0.01 to about 5 moles of the internal electron donor compounds and from about 0.01 to about 500 moles of the titanium compounds are used per mole of the magnesium compound used to make the solid catalyst component. In another embodiment, from about 0.05 to about 2 moles of the internal electron donor compounds and from about 0.05 to about 300 moles of the titanium compounds are used per mole of the magnesium compound used to make the solid catalyst component.

In one embodiment, in the solid catalyst component, the atomic ratio of halogen/titanium is from about 4 to about 200; the internal electron donor/titanium mole ratio is from about 0.01 to about 10; and the magnesium/titanium atomic ratio is from about 1 to about 100. In another embodiment, in the solid catalyst component, the atomic ratio of halogen/titanium is from about 5 to about 100; the internal electron donor/titanium mole ratio is from about 0.2 to about 6; and the magnesium/titanium atomic ratio is from about 2 to about 50.

The resulting solid catalyst component generally contains a magnesium halide of a smaller crystal size than commercial magnesium halides and usually has a specific surface area of at least about 5 m²/g, such as from about 10 to about 1,000 m²/g, or from about 100 to about 800 m²/g. Since the above ingredients are unified to form an integral structure of the solid catalyst component, the composition of the solid catalyst component is not substantially changed by being washed with, for example, hexane.

The solid catalyst component may be used after being diluted with an inorganic or organic compound such as a silicon compound, an aluminum compound, or the like.

Methods of preparing solid catalyst components, which can be used in the present invention, are described in U.S. Pat. Nos. 4,771,023; 4,784,983; 4,829,038; 4,861,847; 4,990,479; 5,177,043; 5,194,531; 5,244,989; 5,438,110; 5,489,634; 5,576,259; 5,767,215; 5,773,537; 5,905,050; 6,323,152; 6,437,061; 6,469,112; 6,962,889; 7,135,531; 7,153,803; 7,271,119; 2004242406; 20040242407; and 20070021573 which are hereby incorporated by reference in this regard.

The catalyst system may contain at least one organoaluminum compound in addition to the solid catalyst component. Compounds having at least one aluminum-carbon bond in the molecule can be used as the organoaluminum compound. Examples of organoaluminum compounds include compounds of the following chemical formula (III):

AlR_(n)X_(3-n)  (III)

In formula (III), R represents a hydrocarbon group usually having 1 to about 20 carbon atoms, X represents a halogen atom, and 0<n≦3.

Specific examples of the organoaluminum compounds represented by formula (III) include, but are not limited to trialkyl aluminums such as triethyl aluminum, tributyl aluminum and trihexyl aluminum; trialkenyl aluminums such as triisoprenyl aluminum; dialkyl aluminum halides such as diethyl aluminum chloride, dibutyl aluminum chloride and diethyl aluminum bromide; alkyl aluminum sesquihalides such as ethyl aluminum sesquichloride, butyl aluminum sesquichloride and ethyl aluminum sesquibromide; alkyl aluminum dihalides such as ethyl aluminum dichloride, propyl aluminum dichloride and butyl aluminum dibromide; dialkyl aluminum hydrides such as diethyl aluminum hydride and dibutyl aluminum hydride; and other partially hydrogenated alkyl aluminums such as ethyl aluminum dihydride and propyl aluminum dihydride.

The organoaluminum compound is used in the catalyst system of the present invention in an amount that the mole ratio of aluminum to titanium (from the solid catalyst component) is from about 5 to about 1,000. In another embodiment, the mole ratio of aluminum to titanium in the catalyst system is from about 10 to about 700. In yet another embodiment, the mole ratio of aluminum to titanium in the catalyst system is from about 25 to about 400.

The catalyst system may contain at least one alkyl benzoate derivative as an external electron donor compound in addition to the solid catalyst component. The alkyl benzoate derivative serves as one component of a Ziegler-Nana catalyst system for olefin polymerization and contributes to the ability to obtain a polyolefin having a controllable molecular weight distribution and controllable crystallinity while retaining high performance with respect to catalytic activity.

The alkyl benzoate derivative is used in the catalyst system in an amount that the mole ratio of the organoaluminum compound to the alkyl benzoate derivative is from about 2 to about 80. In another embodiment, the mole ratio of the organoaluminum compound to the alkyl benzoate derivative is from about 5 to about 70. In yet another embodiment, the mole ratio of the organoaluminum compound to the alkyl benzoate derivative is from about 7 to about 50.

The alkyl benzoate derivative is represented by chemical formula (IV)

wherein R₁′ is C₁-C₆ linear or branched alkyl; and R₂′-R₆′ are independently hydrogen, halogen, C₁-C₆ linear or branched alkyl, or C₁-C₆ linear or branched alkoxyl radicals.

Specific examples of the alkyl benzoate derivative of formula (IV) include, but are not limited to methylbenzoate, ethylbenzoate, propylbenzoate, butylbenzoate, methyl-3-methylbenzoate, ethyl-3-methylbenozate, propyl-3-methylbenozate, butyl-3-methylbenozate, methyl-4-methylbenzoate, ethyl-4-methylbenozate, propyl-4-methylbenozate, butyl-4-methylbenozate, methyl-3-ethylbenzoate, ethyl-3-ethylbenozate, propyl-3-ethylbenozate, butyl-3-ethylbenozate, methyl-4-ethylbenzoate, ethyl-4-ethylbenozate, propyl-4-ethylbenozate, butyl-4-ethylbenozate, methyl-3-propybenzoate, ethyl-3-propylbenozate, propyl-3-propylbenozate, butyl-3-propylbenozate, methyl-4-proplybenzoate, ethyl-4-propylbenozate, propyl-4-propylbenozate, butyl-4-propylbenozate, methyl-3-methoxybenzoate, ethyl-3-methoxybenozate, propyl-3-methoxybenozate, butyl-3-methoxybenozate, methyl-4-methoxybenzoate, ethyl-4-methoxybenozate, propyl-4-methoxybenozate, butyl-4-methoxybenozate, methyl-3-ethoxybenzoate, ethyl-3-ethoxybenozate, propyl-3-ethoxybenozate, butyl-3-ethoxybenozate, methyl-4-ethoxybenzoate, ethyl-4-ethoxybenozate, propyl-4-ethoxybenozate, butyl-4-ethoxybenozate, methyl-3-propoxybenzoate, ethyl-3-propoxybenozate, propyl-3-propoxybenozate, butyl-3-propoxybenozate, methyl-4-propoxybenzoate, ethyl-4-propoxybenozate, propyl-4-propoxybenozate, butyl-4-propoxybenozate, methyl-3-chlorobenzoate, ethyl-3-chlorobenozate, propyl-3-chlorobenozate, butyl-3-chlorobenozate, methyl-4-chlorobenzoate, ethyl-4-chlorobenozate, propyl-4-chlorobenozate, butyl-4-chlorobenozate, methyl-3-bromobenzoate, ethyl-3-bromobenozate, propyl-3-bromobenozate, butyl-3-bromobenozate, methyl-4-bromobenzoate, ethyl-4-bromobenozate, propyl-4-bromobenozate, butyl-4-bromobenozate.

The catalyst system may contain another type of external electron donor compound, an organosilicon compound. The organosilicon compound contains silicon bonded to at least one hydrocarbon group. General examples of hydrocarbon groups include alkyl groups, cycloalkyl groups, (cycloalkyl)methylene groups, alkene groups, aromatic groups, and the like.

In one embodiment, the organosilicon compound is represented by chemical formula (V):

R_(n)Si(OR′)_(4-n)  (V)

wherein each R and R′ independently represent a hydrocarbon group, and n is 0≦n<4.

Specific examples of the organosilicon compound of formula (V) include, but are not limited to trimethylmethoxysilane, trimethylethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diisopropyldimethoxysilane, diisobutyldimethoxysilane, t-butylmethyldimethoxysilane, t-butylmethyldiethoxysilane, t-amylmethyldiethoxysilane, dicyclopentyldimethoxysilane, diphenyldimethoxysilane, phenylmethyldimethoxysilane, diphenyldiethoxysilane, bis-o-tolydimethoxysilane, bis-m-tolydimethoxysilane, bis-p-tolydimethoxysilane, bis-p-tolydiethoxysilane, bisethylphenyldimethoxysilane, dicyclohexyldimethoxysilane, cyclohexylmethyldimethoxysilane, cyclohexylmethyldiethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, vinyltrimethoxysilane, methyltrimethoxysilane, n-propyltriethoxysilane, decyltrimethoxysilane, decyltriethoxysilane, phenyltrimethoxysilane, gamma-chloropropyltrimethoxysilane, methyltriethoxysilane, ethyltriethoxysilane, vinyltriethoxysilane, t-butyltriethoxysilane, n-butyltriethoxysilane, iso-butyltriethoxysilane, phenyltriethoxysilane, gamma-amniopropyltriethoxysilane, cholotriethoxysilane, ethyltriisopropoxysilane, vinyltirbutoxysilane, cyclohexyltrimethoxysilane, cyclohexyltriethoxysilane, 2-norbornanetritnethoxysilane, 2-norbornanetriethoxysilane, 2-norbornanemethyldimethoxysilane, ethyl silicate, butyl silicate, trimethylphenoxysilane, and methyltriallyloxysilane.

In another embodiment, the organosilicon compound is represented by chemical formula (VI):

SiRR′_(m)(OR″)_(3-m)  (VI)

In the above formula (VI), 0≦m<3, such as 0≦m≦2; and R independently represents a cyclic hydrocarbon or substituted cyclic hydrocarbon group. Specific examples of the group R include, but are not limited to cyclopropyl; cyclobutyl; cyclopentyl; 2-methylcyclopentyl; 3-methyleyclopentyl; 2-ethylcyclopentyl; 3-propylcyclopentyl; 3-isopropylcyclopentyl; 3-butylcyclopentyl; 3-tetiary butyl cyclopentyl; 2,2-dimethylcyclopentyl; 2,3-dimethylcyclopentyl; 2,5-dimethylcyclopentyl; 2,2,5-trimethylcyclopentyl; 2,3,4,5-tetramethylcyclopentyl; 2,2,5,5-tetramethylcyclopentyl; 1-cyclopentylpropyl; 1-methyl-1-cyclopentylethyl; cyclopentenyl; 2-cyclopentenyl; 3-cyclopentenyl; 2-methyl-1-cyclopentenyl; 2-methyl-3-cyclopentenyl; 3-methyl-3-cyclopentenyl; 2-ethyl-3-cyclopentenyl; 2,2-dimethyl-3-cyclopentenyl; 2,5-dimethyl-3-cyclopentenyl; 2,3,4,5-tetramethyl-3-cyclopentenyl; 2,2,5,5-tetramethyl-3-cyclopentenyl; 1,3-cyclopentadienyl; 2,4-cyclopentadienyl; 1,4-cyclopentadienyl; 2-methyl-1,3-cyclopentadienyl; 2-methyl-2,4-cyclopentadienyl; 3-methyl-2,4-cyclopentadienyl; 2-ethyl-2,4-cyclopentadienyl; 2,2-dimethyl-2,4-cyclopentadienyl; 2,3-dimethyl-2,4-cyclopentadienyl; 2,5-dimethyl-2,4-cyclopentadienyl; 2,3,4,5-tetramethyl-2,4-cyclopentadienyl; indenyl; 2-methylindenyl; 2-ethylindenyl; 2-indenyl; 1-methyl-2-indenyl; 1,3-dimethyl-2-indenyl; indanyl; 2-methylindanyl; 2-indanyl; 1,3-dimethyl-2-indanyl; 4,5,6,7-tetrahydroindenyl; 4,5,6,7-tetrahydro-2-indenyl; 4,5,6,7-tetrahydro-1-methyl-2-indenyl; 4,5,6,7-tetrahydro-1,3-dimethyl-2-indenyl; fluorenyl groups; cyclohexyl; methylcyclohexyls; ethylcylcohexyls; propylcyclohexyls; isopropylcyclohexyls; n-butylcyclohexyls; tertiary-butyl cyclohexyls; dimethylcyclohexyls; and trimethylcyclohexyls.

In formula (VI), R′ and R″ are identical or different, and each represents a hydrocarbons. Examples of R′ and R″ are alkyl, cycloalkyl, aryl and aralkyl groups having 3 or more carbon atoms. Furthermore, R and R may be bridged by an alkyl group, etc. General examples of organosilicon compounds are those of formula (VI) in which R is cyclopentyl group, R′ is an alkyl group such as methyl or cyclopentyl group, and R″ is an alkyl group, particularly a methyl or ethyl group.

Specific examples of organosilicon compound of formula (VI) include, but are not limited to trialkoxysilanes such as cyclopropyltrimethoxysilane, cyclobutyltrimethoxysilane, cyclopentyltrimethoxysilane, 2-methylcyclopentyltrimethoxysilane, 2,3-dimethyl cyclopentyltrimethoxysilane, 2,5-dimethylcyclopentyltrimethoxysilane, cyclopentyltriethoxysilane, cyclopentenyltrimethoxysilane, 3-cyclopentenyltrimethoxysilane, 2,4-cyclopentadienyltrimethoxysilane, indenyltrimethoxysilane and fluorenyltrimethoxysilane; dialkoxysilanes such as dicyclopentyldimethoxysilane, bis(2-methylcyclopentyl)dimethoxysilane, bis(3-tertiary butylcyclopentyl)dimethoxysilane, bis(2,3-dimethylcyclopentypdimethoxysilane, bis(2,5-dimethylcyclopentyl)dimethoxysilane, dicyclopentyldiethoxysilane, dicyclobutyldiethoxysilane, cyclopropylcyclobutyldiethoxysilane, dicyclopentenyldimethoxysilanc, di(3-cyclopentenyl)dimethoxysilane, bis(2,5-dimethyl-3-cyclopentenyl)dimethoxysilane, di-2,4-cyclopentadienyl)dimethoxysilane, bis(2,5-dimethyl-2,4-cyclopentadienyl)dimethoxysilane, bis(1-methyl-1-cyclopentyl ethyl)dimethoxysilane, cyclopentylcyclopentenyldimethoxysilane, cyclopentylcyclopentadienyldimethoxysilane,diindenyldimethoxysilane, bis(1,3-dimethyl-2-indenyl)dimethoxysilane, cyclopentadienylindenyldimethoxysilane, difluorenyldimethoxysilane, cyclopentylfluorenyldimethoxysilane and indenylfluorenyldimethoxysilane; monoalkoxysilanes such as tricyclopentylmethoxysilane, tricyclopentenylmethoxysilane, tricyclopentadienylmethoxysilane, tricyclopentylethoxysilane, dicyclopentylmethylmethoxysilane, dicyclopentylethylmethoxysilane, dicyclopentylmethylethoxysilane, cyclopentyldimethylmethoxysilane, cyclopentyldiethylmethoxysilane, cyclopentyldimethylethoxysilane, bis(2,5-dimethylcyclopentyncyclopentylmethoxysilane, dicyclopentylcyclopentenylmethoxysilane, dicyclopentylcyclopentenadienylmethoxysilane and diindenylcyclopentylmethoxysilane; and ethylenebis-cyclopentyldimethoxysilane.

Polymerization of olefins in accordance with the present invention is carried out in the presence of the catalyst system described above. Generally speaking, olefins are contacted with the catalyst system described above under suitable conditions to form desired polymer products. In one embodiment, preliminary polymerization described below is carried out before the main polymerization. In another embodiment, polymerization is carried out without preliminary polymerization. In yet another embodiment, the formation of copolymer is carried out using at least two polymerization zones.

In preliminary polymerization, the solid catalyst component is usually employed in combination with at least a portion of the organoaluminum compound. This may be carried out in the presence of part or the whole of the alkyl benzoate derivative and/or the organosilicon compound (external electron donor compounds). The concentration of the catalyst system used in the preliminary polymerization may be much higher than that in the reaction system of the main polymerization.

In preliminary polymerization, the concentration of the solid catalyst component in the preliminary polymerization is usually from about 0.01 to about 200 millimoles, preferably from about 0.05 to about 100 millimoles, calculated as titanium atoms per liter of an inert hydrocarbon medium described below. In one embodiment, the preliminary polymerization is carried out by adding an olefin and the above catalyst system ingredients to an inert hydrocarbon medium and polymerizing the olefin under mild conditions.

Specific examples of the inert hydrocarbon medium include, but are not limited to aliphatic hydrocarbons such as propane, butane, pentane, hexane, heptanes, octane, decane, dodecane and kerosene; alicyclic hydrocarbons such as cyclopentane, cyclohexane and methylcyclopentane; aromatic hydrocarbons such as benzene, toluene and xylene; and mixtures thereof. In the present invention, a liquid olefin may be used in place of part or the whole of the inert hydrocarbon medium.

The olefin used in the preliminary polymerization may be the same as, or different from, an olefin to be used in the main polymerization.

The reaction temperature for the preliminary polymerization is sufficient for the resulting preliminary polymer to not substantially dissolve in the inert hydrocarbon medium. In one embodiment, the temperature is from about −20 degrees Celsius to about 100 degrees Celsius. In another embodiment, the temperature is from about −10 degrees Celsius to about 80 degrees Celsius. In yet another embodiment, the temperature is from about 0 degrees Celsius to about 40 degrees Celsius.

Optionally, a molecular-weight controlling agent, such as hydrogen, may be used in the preliminary polymerization. The molecular weight controlling agent is used in such an amount that the polymer obtained by the preliminary polymerization has an intrinsic viscosity, measured in decalin at 135 degrees Celsius, of at least about 0.2 dl/g, and preferably from about 0.5 to about 10 dl/g.

In one embodiment, the preliminary polymerization is desirably carried out so that from about 0.1 g to about 1,000 g of a polymer is formed per gram of the solid catalyst component of the catalyst system. In another embodiment, the preliminary polymerization is desirably carried out so that from about 0.3 g to about 500 g of a polymer is formed per gram of the solid catalyst component. If the amount of the polymer formed by the preliminary polymerization is too large, the efficiency of producing the olefin polymer in the main polymerization may sometimes decrease, and when the resulting olefin polymer is molded into a film or another article, fish eyes tend to occur in the molded article. The preliminary polymerization may be carried out batchwise or continuously.

After the preliminary polymerization conducted as above, or without performing any preliminary polymerization, the main polymerization of an olefin is carried out in the presence of the above-described olefin polymerization catalyst system formed from the solid catalyst component, the organoaluminum compound and the alkyl benzoate derivative and/or the organosilicon compound (external electro donor compounds).

Examples of olefins that can be used in the main polymerization are alpha-olefins having 2 to 20 carbon atoms such as ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-pentene, 1-octene, 1-hexene, 3-methyl-1-pentene, 3-methyl-1-butene, 1-decene, 1-tetradecene, 1-eicosene, and vinylcyclohexane. In the process of the present invention, these alpha-olefins may be used individually or in any combination.

In one embodiment, propylene or 1-butene is homopolymerized, or a mixed olefin containing propylene or 1-butene as a main component is copolymerized. When the mixed olefin is used, the proportion of propylene or 1-butene as the main component is usually at least about 50 mole %, preferably at least about 70 mole %.

By performing the preliminary polymerization, the catalyst system in the main polymerization can be adjusted in the degree of activity. This adjustment tends to result in a powdery polymer having a high bulk density. Furthermore, when the preliminary polymerization is carried out, the particles shape of the resulting polymer becomes spherical, and in the case of slurry polymerization, the slurry attains excellent characteristics while in the case of gas phase polymerization, the polymer seed bed attains excellent characteristics. Furthermore, in these embodiments, a polymer having a high stereoregularity index can be produced with a high catalytic efficiency by polymerizing an alpha-olefin having at least 3 carbon atoms. Accordingly, when producing the propylene copolymer, the resulting copolymer powder or the copolymer becomes easy to handle.

In the homopolymerization of these olefins, a polyunsaturated compound such as conjugated diene or non-conjugated diene may be used as a comonomer. Examples of comonomers include styrene, butadiene, acrylonitrile, acrylamide, alpha-methyl styrene, chlorostyrene, vinyl toluene, divinyl benzene, diallyphthalate, alkyl methacrylates and alkyl acrylates. In one embodiment, the comonomers include thermoplastic and elastomeric monomers.

The main polymerization of an olefin is carried out usually in the gaseous or liquid phase. In one embodiment, polymerization (main polymerization) employs a catalyst system containing the solid catalyst component in an amount from about 0.001 to about 0.75 millimoles calculated as Ti atom per liter of the volume of the polymerization zone, and the organoaluminum compound in an amount from about 1 to about 2,000 moles and the alkyl benzoate derivative in an amount from about 0.001 to about 10 moles per mole of titanium atoms in the solid catalyst component. In another embodiment, polymerization employs a catalyst system containing the solid catalyst component in an amount of from 0.005 to about 0.5 milimoles calculated as Ti atom per liter of the volume of the polymerization zone, and the organoaluminum compound in an amount from about 5 to about 500 moles and the alkyl benzoate derivative in an amount from about 0.01 to about 2 moles per mole of titanium atoms in the solid catalyst component. In yet another embodiment, polymerization employs a catalyst system containing the alkyl benzoate derivative in an amount from about 0.005 to about 1 mole per mole of titanium atoms in the solid catalyst component. When the organoaluminum compound and the alkyl benzoate derivative are used partially in the preliminary polymerization, the catalyst system subjected to the preliminary polymerization is used together with the remainder of the catalyst system components. The catalyst system subjected to the preliminary polymerization may contain the preliminary polymerization product.

The use of hydrogen at the time of polymerization promotes and contributes to control of the molecular weight of the resulting polymer, and the polymer obtained may have a high melt flow rate. In this case, the stereoregularity index of the resulting polymer and the activity of the catalyst system are increased according to the methods of the present invention.

In one embodiment, the polymerization temperature is from about 20 degree Celsius to about 200 degrees Celsius. In another embodiment, the polymerization temperature is from about 50 degree Celsius to about 180 degrees Celsius. In one embodiment, the polymerization pressure is typically from atmospheric pressure to about 100 kg/cm². In another embodiment, the polymerization pressure is typically from about 2 kg/cm² to about 50 kg/cm². The main polymerization may be carried out batchwise, semi-continuously or continuously. The polymerization may also be carried out in two or more stages under different reaction conditions.

The olefin polymer so obtained may be a homopolymer, a random copolymer, a block copolymer or an impact copolymer. The impact copolymer contains an intimate mixture of a polyolefin homopolymer and a polyolefin rubber. Examples of polyolefin rubbers include ethylene propylene rubber (EPR) such as ethylene propylene methylene copolymer rubber (EPM) and ethylene propylene diene methylene terpolymer rubber (EPDM).

The olefin polymer obtained by using the catalyst system has a very small amount of an amorphous polymer component and therefore a small amount of a hydrocarbon-soluble component. Accordingly, a film molded from the resultant polymer has low surface tackiness.

The polyolefin obtained by the polymerization process is excellent in particle size distribution, particle diameter and bulk density, and the copolyolefin obtained has a narrow composition distribution. In an impact copolymer, excellent fluidity, low temperature resistance, and a desired balance between stiffness and elasticity can be obtained.

In one embodiment, propylene and an alpha-olefin having 2 or from about 4 to about 20 carbon atoms are copolymerized in the presence of the catalyst system described above. The catalyst system may be one subjected to the preliminary polymerization described above. In another embodiment, propylene and an ethylene rubber are formed in two reactors coupled in series to form an impact polymer.

The alpha-olefin having 2 carbon atoms is ethylene, and examples of the alpha-olefin having about 4 to about 20 carbon atoms are 1-butene, 1-pentene, 4-methyl-1-pentene, 1-octene, 1-hexene, 3-methyl-1-pentene, 3-methyl-1-butene, 1-decene, vinylcyclohexane, 1-tetradecene, and the like.

In the main polymerization, propylene may be copolymerized with two or more such alpha-olefins. For example, it is possible to copolymerize propylene with ethylene and 1-butene. In one embodiment, propylene is copolymerized with ethylene, 1-butene or ethylene and 1-butene.

Block copolymerization of propylene and another alpha-olefin may be carried out in two stages. The polymerization in a first stage may be the homopolymerization of propylene or the copolymerization of propylene with the other alpha-olefin. In one embodiment, the amount of the monomers polymerized in the first stage is from about 50 to about 95% by weight. In another embodiment, the amount of the monomers polymerized in the first stage is from about 60 to about 90% by weight. In the present invention, this first stage polymerization may, as required be carried out in two or more stages under the same or different polymerization conditions.

In one embodiment, the polymerization in a second stage is desirably carried out such that the mole ratio of propylene to the other alpha-olefin(s) is from about 10/90 to about 90/10. In another embodiment, the polymerization in a second stage is desirably carried out such that the mole ratio of propylene to the other alpha-olefin(s) is from about 20/80 to about 80/20. In yet another embodiment, the polymerization in a second stage is desirably carried out such that the mole ratio of propylene to the other alpha-olefin(s) is from about 30/70 to about 70/30. Producing a crystalline polymer or copolymer of another alpha-olefin may be provided in the second polymerization stage.

The propylene copolymer so obtained may be a random copolymer or the above-described block copolymer. This propylene copolymer typically contains from about 7 to about 50 mole % of units derived from the alpha-olefin having 2 or from about 4 to about 20 carbon atoms. In one embodiment, a propylene random copolymer contains from about 7 to about 20 mole % of units derived from the alpha-olefin having 2 or from about 4 to about 20 carbon atoms. In another embodiment, the propylene block copolymer contains from about 10 to about 50 mole % of units derived from the alpha-olefin having 2 or 4-20 carbon atoms.

In another embodiment, copolymers made with the catalyst system contain from about 50% to about 99% by weight poly-alpha-olefins and from about 1% to about 50% by weight comonomers (such as thermoplastic or elastomeric monomers). In another embodiment, copolymers made with the catalyst system contain from about 75% to about 98% by weight poly-alpha-olefins and from about 2% to about 25% by weight comonomers.

It should be understood that where there is no reference to the polyunsaturated compound that can be used, the method of polymerization, the amount of the catalyst system and the polymerization conditions, the same description as the above embodiment are applicable.

The catalysts/methods of the present invention can be in some instances lead to the production of poly-alpha-olefins having xylene soluble (XS) from about 0.5% to about 10%. In another embodiment, poly-alpha-olefins having xylene soluble (XS) from about 1.5% to about 8% are produced in accordance with the present invention. XS refers to the percent of solid polymer that dissolves into xylene. A low XS % value generally corresponds to a highly isotactic polymer (i.e. higher crystallinity), whereas a high XS % value generally corresponds to a low isotactic polymer.

In one embodiment, the catalyst efficiency (measured as kilogram of polymer produced per gram of catalyst) of the catalyst system of the present invention is at least about 30. In another embodiment, the catalyst efficiency of the catalyst system of the present invention is at least about 60.

The catalysts/methods of the present invention can in some instances lead to the production of poly-alpha-olefins having melt flow indexes (MFI) from about 0.1 to about 300. The MFI is measured according to ASTM standard D1238. In another embodiment, poly-alpha-olefins having an MFI from about 5 to about 30 are produced in accordance with the present invention. In one embodiment, an impact polypropylene-ethylenepropylene rubber product has an MFI from about 4 to about 10. In another embodiment, an impact polypropylene-ethylenepropylene rubber product has an MFI from about 5 to about 9. In some instances a relatively high MFI indicates relatively a high catalyst efficiency is obtainable.

The catalysts/methods of the present invention can in some instances lead to the production of poly-alpha-olefins having bulk densities (BD) of at least about 0.3 cc/g. In another embodiment, poly-alpha-olefins having a BD of at least about 0.4 cc/g are produced in accordance with the present invention.

In one embodiment, an impact polypropylene-ethylenepropylene rubber product having a BD of at least about 0.3 cc/g is produced in accordance with the present invention. In another embodiment, an impact polypropylene-ethylenepropylene rubber product having a BD of at least about 0.4 cc/g is produced in accordance with the present invention.

The catalysts/methods of the present invention lead to the production of poly-alpha-olefins having a relatively narrow molecular weight distribution. In one embodiment, the Mw/Mn of a polypropylene polymer made with the catalyst system is from about 2 to about 6. In another embodiment, the Mw/Mn of a polypropylene polymer made with the catalyst system is from about 3 to about 5.

The present invention can lead to the production of a propylene block copolymer and impact copolymers including polypropylene based impact copolymer having one or more excellent melt-flowability, moldability desirable balance between rigidity and elasticity, good stereospecific control, good control over polymer particle size, shape, size distribution, and molecular weight distribution, and impact strength with a high catalytic efficiency and/or good operability. Employing the catalyst systems containing the solid catalyst component according to the present invention yields catalysts simultaneously having high catalytic efficiency, and one or more of excellent melt-flowability, extrudability, moldability, rigidity-elasticity and impact strength.

Examples of systems for polymerizing olefins are now described. Referring to FIG. 1, a high level schematic diagram of a system 10 for polymerizing olefins is shown, Inlet 12 is used to introduce into a reactor 14 catalyst system components, olefins, optional comonomers, hydrogen gas, fluid media, pH adjusters, surfactants, and any other additives. Although only one inlet is shown, many often are employed. Reactor 14 is any suitable vehicle in which olefins can be polymerized. Examples of reactor 14 include a single reactor, a series of two or more reactors, slurry reactors, fixed bed reactors, gas phase reactors, fluidized gas reactors, loop reactors, multizone circulating reactors, and the like. Once polymerization is complete, or as polyolefins are produced, the polymer product is removed from the reactor 14 via outlet 16 which leads to a collector 18. Collector 18 may include downstream processing, such as heating, extrusion, molding, and the like.

Referring to FIG. 2, a schematic diagram of a multizone circulating reactor 20 that can be employed as the reactor 14 in FIG. 1 or the reactor 44 in FIG. 3 for making polyolefins is shown. The multizone circulating reactor 20 substitutes a series of separate reactors with a single reactor loop that permits different gas phase polymerization conditions in two sides due to use of a liquid barrier. In the multizone circulating reactor 20, a first zone starts out rich in olefin monomers, and optionally one or more comonomers. A second zone is rich in hydrogen gas, and a high velocity gas flow divides the growing resin particles out loosely. The two zones produce resins of different molecular weights and/or monomer compositions. Polymer granules grow as they circulate around the loop, building up alternating layers of each polymer fraction in an onion like fashion. Each polymer particle constitutes an intimate combination of both polymer fractions.

In operation, the polymer particles pass up through the fluidizing gas in an ascending side 24 of the loop and come down through the liquid monomer on a descending side 26. The same or different monomers (and again optionally one or more comonomers) can be added in the two reactor legs. The catalyst system described above is used in the reactor.

In the liquid/gas separation zone 30, hydrogen gas is removed to cool and recirculate. Polymer granules are then packed into the top of the descending side 26, where they then descend. Monomers are introduced as liquids in this section. Conditions in the top of the descending side 26 can be varied with different combinations and/or proportions of monomers in successive passes.

Referring to FIG. 3, a high level schematic diagram of another system 40 for polymerizing olefins is shown. This system is ideally suited to make impact polymers. A reactor 44, such as a single reactor, a series of reactors, or a multizone circulating reactor is paired with a gas phase or a fluidized bed reactor 48 downstream containing the catalyst systems described above to make impact copolymers with desirable impact to stiffness balance or greater softness than those made with conventional catalyst systems. Inlet 42 is used to introduce into the reactor 44 catalyst system components, olefins, optional comonomers, hydrogen gas, fluid media, pH adjusters, surfactants, and any other additives. Although only one inlet is shown, many often are employed. Through transfer means 46 the polyolefin made in the first reactor 44 is sent to a second reactor 48. Feed 50 is used to introduce catalyst system components, olefins, optional comonomers, fluid media, and any other additives. The second reactor 48 may or may not contain catalyst system components. Again, although only one inlet is shown, many often are employed. Once the second polymerization is complete, or as impact copolymers are produced, the polymer product is removed from the second reactor 48 via outlet 52 which leads to a collector 54. Collector 54 may include downstream processing, such as heating, extrusion, molding, and the like. At least one of the first reactor 44 and the second reactor 48 contains catalyst systems in accordance with the invention.

When making an impact copolymer, polypropylene can be formed in the first reactor while an ethylene propylene rubber can be formed in the second reactor. In this polymerization, the ethylene propylene rubber in the second reactor is formed with the matrix (and particularly within the pores) of the polypropylene formed in the first reactor. Consequently, an intimate mixture of an impact copolymer is formed, wherein the polymer product appears as a single polymer product. Such an intimate mixture cannot be made by simply mixing a polypropylene product with an ethylene propylene rubber product.

Although not shown in any of the figures, the systems and reactors can be controlled, optionally with feedback based on continuous or intermittent testing, using a processor equipped with an optional memory and controllers. For example, a processor may be connected to one or more of the reactors, inlets, outlets, testing/measuring systems coupled with the reactors, and the like to monitor and/or control the polymerization process, based on preset data concerning the reactions, and/or based on testing/measuring data generated during a reaction. The controller may control valves, flow rates, the amounts of materials entering the systems, the conditions (temperature, reaction time, pH, etc.) of the reactions, and the like, as instructed by the processor. The processor may contain or be coupled to a memory that contains data concerning various aspects of the polymerization process.

With respect to any figure or numerical range for a given characteristic, a figure or a parameter from one range may be combined with another figure or a parameter from a different range for the same characteristic to generate a numerical range.

Other than in the operating examples, or where otherwise indicated, all numbers, values and/or expressions referring to quantities of ingredients, reaction conditions, etc., used in the specification and claims are to be understood as modified in all instances by the term “about.”

The following examples illustrate the present invention. Unless otherwise indicated in the following examples and elsewhere in the specification and claims, all parts and percentages are by weight, all temperatures are in degrees Celsius, and pressure is at or near atmospheric pressure.

Example 1

Into a one liter Buchi reactor under N₂ added a mixture of 13.2 g MgCl₂, 203.7 g toluene, 25.7 g epichlorohydrin, and 26.8 g tributylphosphate. The mixture was heated for five hours while agitating at 400 rpm and 60° C.; then 3.2 g phthalic anhydride was added and the mixture was agitated under the same conditions for one hour. The reaction mixture was cooled to −30° C. and 261 g of TiCl₄ was added slowly while maintaining the reactor temperature below −26° C. After the addition the agitation rate was reduced to 200 rpm and the temperature was ramped from −26° C. to 0° C. in one hour then from 0° C. to 85° C. in one hour.

The agitation rate was raised to 400 rpm and the mixture was held at 85° C. for 30 minutes. 4.2 g of 9-(hexylcarbonyl)-9′-methoxymethylfluorene was added and the mixture was stirred at 85° C. for one hour then filtered. The solids were re-suspended in 150 ml of toluene and 2.2 g of 9-(hexylcarbonyl)-9′-methoxymethylfluorene was added to the reactor. The mixture was agitated for one hour at 85° C. and 400 rpm. After filtration and washed twice with 260 ml toluene the mixture was left over night in the second wash toluene under N₂.

After filtering off the toluene added 265 ml of 10-vol % TiCl₄ in toluene then heated to and held at 105° C. with 400 rpm agitation for one hour. The solids were filtered then re-suspended in 265 ml of 10-vo % TiCl₄ in toluene. The mixture was held at 110° C. for thirty minutes after which the solids were once again filtered. This step was repeated one more time. The final catalyst was washed four times with 160 ml of hexane then discharged from the reactor in hexane.

Propylene polymerization was performed in a gallon reactor. The reactor was purged at 100° C. under nitrogen for one hour. At room temperature, 1.5 ml of 25-wt % triethylaluminum (TEAL) in heptane was added into the reactor. Then 0.75 ml of 0.0768 M solution of ethylbenzoate followed by 0.75 ml of 1 wt % catalyst slurry in hexane was added into the reactor. The reactor was pressurized with H₂ to 4.0 psig then charged with 1500 ml liquid propylene. The reactor was heated to then held at 70° C. for one hour. At the end of the hold, the reactor was vented and the polymer was recovered.

Yields: 495 g polypropylene. Catalyst activity: 66.0 kg/g. Xylene soluble: 7.6%.

MFR: 29.4 dg/min.

Example 2

The polymerization was performed under the same conditions as Example 1 except 10.0 psig H₂ was added in the propylene polymerization.

Yield: 590 g polypropylene. Catalyst activity: 78.7 kg/g. Xylene soluble: 7.7%.

MFR: 109.00 dg/min.

Example 3

The polymerization was performed under the same conditions as Example 1 except 20.0 psig H₂ was added in the propylene polymerization.

Yield: 598 g polypropylene. Catalyst activity: 79.7 kg/g. Xylene soluble: 7.6%.

MFR: 300.0 dg/min.

Example 4

The polymerization was performed under the same conditions as Example 1 except 0.75 ml of 0.0768 M solution of ethyl-4-ethoxybenzenoate was added in the propylene polymerization.

Yield: 525 g polypropylene. Catalyst activity: 70.0 kg/g. Xylene soluble: 7.6%.

MFR: 24.2 dg/min.

Example 5

The polymerization was performed under the same conditions as Example 4 except 10.0 psig H₂ was added in the propylene polymerization.

Yield: 564 g polypropylene. Catalyst activity: 75.2 kg/g. Xylene soluble: 7.6%.

MFR: 99.0 dg/min.

Example 6

The polymerization was performed under the same conditions as Example 4 except 20.0 psig H₂ was added in the propylene polymerization.

Yield: 581 g polypropylene. Catalyst activity: 77.5 kg/g. Xylene soluble: 7.6%.

MFR: 291.0 dg/min.

Example 7

The polymerization was performed under the same conditions as Example 1 except 0.75 ml of 0.0768 M solution of ethyl-4-methylbenzoate was added in the propylene polymerization.

Yield: 475 g polypropylene. Catalyst activity: 63.3 kg/g. Xylene soluble: 7.5%.

MFR: 30.8 dg/min.

Example 8

The polymerization was performed under the same conditions as Example 7 except 10.0 psig H₂ was added in the propylene polymerization.

Yield: 531 g polypropylene. Catalyst activity: 70.8 kg/g. Xylene soluble: 7.6%.

MFR: 99.8 dg/min.

Example 9

The polymerization was performed under the same conditions as Example 7 except 20.0 psig H₂ was added in the propylene polymerization.

Yield: 589 g polypropylene. Catalyst activity: 78.5 kg/g. Xylene soluble: 7.7%.

MFR: 295.0 dg/min.

Comparative Example 1

The polymerization was performed under the same conditions as Example 1 except cyclohexylmethyldimethoxysilane instead of ethylbenzoate was added in the propylene polymerization.

Yield: 521 g polypropylene. Catalyst activity: 69.5 kg/g. Xylene soluble: 4.4%.

MFR: 10.2 dg/min.

Comparative Example 2

The polymerization was performed under the same conditions as Example 2 except cyclohexylmethyldimethoxysilane instead of ethylbenzoate was added in the propylene polymerization.

Yield: 568 g polypropylene. Catalyst activity: 75.7 kg/g. Xylene soluble: 4.6%.

MFR: 32.9 dg/min.

Comparative Example 3

The polymerization was performed under the same conditions as Example 3 except cyclohexylmethyldimethoxysilane instead of ethylbenzoate was added in the propylene polymerization.

Yield: 501 g polypropylene. Catalyst activity: 66.8 kg/g. Xylene soluble: 4.8%.

MFR: 80.6 dg/min.

It is, of course, not possible to describe every conceivable combination of the components or methodologies for purpose of describing the disclosed information, but one of ordinary skill in the art can recognize that many further combinations and permutations of the disclosed information are possible. Accordingly, the disclosed information is intended to embrace all such alternations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes,” “has,” “involve,” or variants thereof is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. 

1. A catalyst system for use in olefinic polymerization, comprising: (i) a solid catalyst component comprising titanium, magnesium, halogen and an internal electron donor compound; (ii) an organoaluminum compound; and (iii) an alkyl benzoate derivative, wherein the internal electron donor compound comprises at least one ether group and at least one ketone group.
 2. The catalyst system according to claim 1, wherein the solid catalyst component comprises a titanium compound having at least one titanium-halogen bond and the internal electron donor compound supported on a magnesium halide crystal lattice.
 3. The catalyst system according to claim 2, wherein the solid catalyst component comprises a titanium compound having at least one titanium-halogen bond and the internal electron donor compound supported on a magnesium dichloride crystal lattice.
 4. The catalyst system according to claim 2 or 3, wherein the titanium compound is TiCl₄ or TiCl₃.
 5. A catalyst system for use in olefinic polymerization, comprising: (i) a solid catalyst component comprising a reaction product of a titanium compound, a magnesium compound, and an internal electron donor compound; (ii) an organoaluminum compound; and (iii) an alkyl benzoate derivative, wherein the internal electron donor compound comprises at least one ether group and at least one ketone group.
 6. The catalyst system according to claim 5, wherein the magnesium compound is a magnesium halide, an alkoxy magnesium halide, an aryloxy magnesium halide, an aryloxy magnesium, or a carboxylic acid salt of magnesium.
 7. The catalyst system according to claim 5, wherein the titanium compound has a general formula: TiX_(n)(OR)_(4-n), wherein R is a hydrocarbon radical having 1 to about 20 carbon atoms, X is a halogen, and n is from 1 to
 4. 8. The catalyst system according to claim 1 or 5, wherein the internal electron donor compound comprises a compound represented by a general formula (I):

wherein R¹, R², R³, and R⁴ are identical or different and are each independently a substituted or unsubstituted hydrocarbon group comprising from 1 to about 30 carbon atoms.
 9. The catalyst system according to claim 1 or 5, wherein the internal electron donor compound comprises a compound represented by a general formula (I):

wherein R¹, R², R³, and R⁴ are identical or different and are each independently a linear or branched alkyl group comprising from 1 to about 18 carbon atoms, a cycloaliphatic group comprising from about 3 to about 18 carbon atoms, an aryl group comprising from about 6 to about 18 carbon atoms, an alkylaryl group comprising from about 7 to about 18 carbon atoms, or an arylalkyl group comprising from about 7 to about 18 carbon atoms.
 10. The catalyst system according to claim 1 or 5, wherein the internal electron donor compound comprises a compound represented by a general formula (I):

wherein R¹, R², R³, and R⁴ are identical or different and are each independently a substituted or unsubstituted hydrocarbon group, and R¹, C¹, and R² are part of a substituted or unsubstituted cyclic or polycyclic structure comprising from about 5 to about 20 carbon atoms.
 11. The catalyst system of claim 10, wherein the cyclic or polycylic structure comprises one or more substitutes selected from the group consisting of linear or branched alkyl groups comprising from 1 to about 18 carbon atoms, cycloaliphatic groups comprising from about 3 to about 18 carbon atoms, aryl groups comprising from about 6 to about 18 carbon atoms, alkylaryl groups comprising from about 7 to about 18 carbon atoms, and arylalkyl groups comprising from about 7 to about 18 carbon atoms.
 12. The catalyst system of claim 1 or 5, wherein the internal electron donor compound comprises at least one selected from the group consisting of 9-(alkylcarbonyl)-9′-alkoxymethylfluorene including 9-(methylcarbonyl)-9′-methoxymethylfluorene, 9-(methylcarbonyl)-9′-ethoxymethylfluorene, 9-(methylcarbonyl)-9′-propoxymethylfluorene, 9-(methylcarbonyl)-9′-butoxymethylfluorene, 9-(methylcarbonyl)-9′-pentoxymethylfluorene, 9-(ethylcarbonyl)-9′-methoxymethylfluorene, 9-(ethylcarbonyl)-9′-ethoxymethylfluorene, 9-(ethylcarbonyl)-9′-propoxymethylfluorene, 9-(ethylcarbonyl)-9′-butoxymethylfluorene, 9-(ethylcarbonyl)-9′-pentoxymethylfluorene, 9-(propylcarbonyl)-9′-methoxymethylfluorene, 9-(propylcarbonyl)-9′-ethoxymethylfluorene, 9-(propylcarbonyl)-9′-propoxymethylfluorene, 9-(propylcarbonyl)-9′-butoxymethylfluorene, 9-(propylcarbonyl)-9′-pentoxymethylfluorene, 9-(butylcarbonyl)-9′-methoxymethylfluorene, 9-(butylcarbonyl)-9′-ethoxymethylfluorene, 9-(butylcarbonyl)-9′-propoxymethylfluorene, 9-(butylcarbonyl)-9′-butoxymethylfluorene, 9-(butylcarbonyl)-9′-pentoxymethylfluorene, 9-(isobutylcarbonyl)-9′-methoxymethylfluorene, 9-(isobutylcarbonyl)-9′-ethoxymethylfluorene, 9-(isobutylcarbonyl)-9′-propoxymethylfluorene, 9-(isobutylcarbonyl)-9′-butoxymethylfluorene, 9-(isobutylcarbonyl)-9′-pentoxymethylfluorene, 9-(pentylcarbonyl)-9′-methoxymethylfluorene, 9-(pentylcarbonyl)-9′-ethoxymethylfluorene, 9-(pentylcarbonyl)-9′-propoxymethylfluorene, 9-(pentylcarbonyl)-9′-butoxymethylfluorene, 9-(pentylcarbonyl)-9′-pentoxymethylfluorene, 9-(hexylcarbonyl)-9′-methoxymethylfluorene, 9-(hexylcarbonyl)-9′-ethoxymethylfluorene, 9-(hexylcarbonyl)-9′-propoxymethylfluorene, 9-(hexylcarbonyl)-9′-butoxymethylfluorene, 9-(hexylcarbonyl)-9′-pentoxymethylfluorene, 9-(octylcarbonyl)-9′-methoxymethylfluorene, 9-(octylcarbonyl)-9′-ethoxymethylfluorene, 9-(oetylcarbonyl)-9′-propoxymethylfluorene, 9-(octylcarbonyl)-9′-butoxymethylfluorene, 9-(octylcarbonyl)-9′-pentoxymethylfluorene, 9-(i-octylcarbonyl)-9′-methoxymethylfluorene, 9-(i-octylcarbonyl)-9′-ethoxymethylfluorene, 9-(i-octylcarbonyl)-9′-propoxymethylfluorene, 9-(i-octylcarbonyl)-9′-butoxymethylfluorene, 9-(i-octylcarbonyl)-9′-pentoxymethylfluorene, 9-(nonylcarbonyl)-9′-methoxymethylfluorene, 9-(nonylcarbonyl)-9′-ethoxymethylfluorene, 9-(nonylcarbonyl)-9′-propoxymethylfluorene, 9-(nonylcarbonyl)-9′-butoxymethylfluorene, 9-(nonylcarbonyl)-9′-pentoxymethylfluorene; 9-(i-nonylcarbonyl)-9′-methoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-ethoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-propoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-butoxymethylfluorene, 9-(i-nonylcarbonyl)-9′-pentoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-methoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-ethoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-propoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-butoxymethylfluorene, 9-(2-ethyl-hexylcarbonyl)-9′-pentoxymethylfluorene, 9-(phenylketone)-9′-methoxymethylfluorene, 9-(phenylketone)-9′-ethoxymethylfluorene, 9-(phenylketone)-9′-propoxymethylfluorene, 9-(phenylketone)-9′-butoxymethylfluorene, 9-(phenylketone)-9′-pentoxymethylfluorene, 9-(4-methylphenylketone)-9′-methoxymethylfluorene, 9-(3-methylphenylketone)-9″-methoxymethylfluorene, and 9-(2-methylphenylketone)-9′-methoxymethylfluorene.
 13. The catalyst system according to claim 1 or 5, wherein the alkyl benzoate derivative having a general formula (II):

wherein R₁′ is C₁-C₆ linear or branched alkyl; and R₂′-R₆′ are independently hydrogen, halogen, C₁-C₆ linear or branched alkyl, or C₁-C₆ linear or branched alkoxyl radicals.
 14. The catalyst system according to claim 13, wherein the alkyl benzoate derivative of the formula (II) comprises at least one selected from group consisting of methylbenzoate, ethylbenzoate, propylbenzoate, butylbenzoate, methyl-3-methylbenzoate, ethyl-3-methylbenozate, propyl-3-methylbenozate, butyl-3-methylbenozate, methyl-4-methylbenzoate, ethyl-4-methylbenozate, propyl-4-methylbenozate, butyl-4-methylbenozate, methyl-3-ethylbenzoate, ethyl-3-ethylbenozate, propyl-3-ethylbenozate, butyl-3-ethylbenozate, methyl-4-ethylbenzoate, ethyl-4-ethylbenozate, propyl-4-ethylbenozate, butyl-4-ethylbenozate, methyl-3-propybenzoate, ethyl-3-propylbenozate, propyl-3-propylbenozate, butyl-3-propylbenozate, methyl-4-proplybenzoate, ethyl-4-propylbenozate, propyl-4-propylbenozate, butyl-4-propylbenozate, methyl-3-methoxybenzoate, ethyl-3-methoxybenozate, propyl-3-methoxybenozate, butyl-3-methoxybenozate, methyl-4-methoxybenzoate, ethyl-4-methoxybenozate, propyl-4-methoxybenozate, butyl-4-methoxybenozate, methyl-3-ethoxybenzoate, ethyl-3-ethoxybenozate, propyl-3-ethoxybenozate, butyl-3-ethoxybenozate, methyl-4-ethoxybenzoate, ethyl-4-ethoxybenozate, propyl-4-ethoxybenozate, butyl-4-ethoxybenozate, methyl-3-propoxybenzoate, ethyl-3-propoxybenozate, propyl-3-propoxybenozate, butyl-3-propoxybenozate, methyl-4-propoxybenzoate, ethyl-4-propoxybenozate, propyl-4-propoxybenozate, butyl-4-propoxybenozate, methyl-3-chlorobenzoate, ethyl-3-chlorobenozate, propyl-3-chlorobenozate, butyl-3-chlorobenozate, methyl-4-chlorobenzoate, ethyl-4-chlorobenozate, propyl-4-chlorobenozate, butyl-4-chlorobenozate, methyl-3-bromobenzoate, ethyl-3-bromobenozate, propyl-3-bromobenozate, butyl-3-bromobenozate, methyl-4-bromobenzoate, ethyl-4-bromobenozate, propyl-4-bromobenozate, and butyl-4-bromobenozate.
 15. The catalyst system according claim 1 or 5, wherein the solid catalyst component having a surface area (by B.E.T. method) between about 10 and about 1,000 m²/g.
 16. The catalyst system according to claim for 5, wherein the oragnoaluminum compound is an alkyl-aluminum compound.
 17. The catalyst system of claim 16, wherein the alkyl-aluminum compound is a trialkyl aluminum compound.
 18. The catalyst system of claim 17, wherein the trialkyl aluminum compound is selected from the group consisting of triethylaluminum, triisobutylaluminum, and tri-n-octylaluminum.
 19. The catalyst system according to claim 1 or 5, wherein the ratio of the solid catalyst component (i) to the organoaluminum compound (II) and to the alkyl benzoate derivative (iii) is about 1:5-1000:1-500, in terms of molar ratio of titanium:aluminum:alkyl benzoate derivative.
 20. A process for polymerizing or copolymerizing an olefin, comprising the steps of: (i) providing the catalyst system according to claim 1 or 5; (ii) polymerizing or copolymerizing the olefin in the presence of the catalyst system to form a polymer or a copolymer; and (iii) recovering the polymer or the copolymer.
 21. The process according to claim 20, wherein the olefin is selected from the group consisting of ethylene, propylene, 1-butylene, 4-methyl-1-pentent, 1-hexene and 1-octene. 